Mercury relay



March 7, 1967 J. V. KOPPENSTEINER MERCURY RELAY Filed Deo. 26, 1961 FIG.1

INVENTOR.

JAMES V. KOPPENSTEINER ATTY,

United States Patent Office 3,3%,409 Patented Mar. 7, 1967 3,308,469 MERCURY RELAY James V. Koppensteiner, Chicago, lil., assigner to Automatic Electric Laboratories, Inc., Northlaire, lill., a corporation of Delaware Fiied Dec. 26, 1961, Ser. No. 161,366

3 Claims. (Cl. S35-151) This case relates to relays and more particularly to relays which have as their switching element mercurywetted contact switch capsules.

Heretofore, it has been known to construct relays of the above type to include several mercury capsules which were placed within a hollow of a tubular coil spool made of an insulating material. In other words, with these prior art relays themercury capsules were placed in one common-hollow of the spool. To prevent movement of the capsules with respect to each other and with respect i to the spool it has heretofore been necessary and common practice to at least partially wrap the capsules with a tape or other similar product in order to fill the gap or space between the hollow and the capsules. This auxiliary means then served to maintain the switch capsules in their position within the common hollow of the spool. In some instances this means was supplemented by a iinal assembly operationl which consisted of attempting to ll all the spaces or voids remaining in the lrelay enclosure after assembly with awax or an epoxy material. However, even when the wax supplemented the tape, for example, there remained no positive assurance as to the amount of support the vital switch capsules had in the relay. This was primarily due to the fact that the aforementioned voids could vconceivably act as air pockets or air traps and thus prevent the flow of the wax therein.

The relay according to the present invention, on the other hand, due to its construction eliminates the need for-any auxiliary means to separate and support the switch capsules within the spool. Furthermore, this is accomplished with a more simplified .relay design hereafter described.

The principal object of the invention therefore is to provide an enclosed relay, particularly of a mercurywetted contact type, with a more positive yet more simplified means for supporting the switching elements used therewith.

Another object of the invention is to provide such a relay whose cost of manufacture is reduced by the use of a spool that can be standard to a variety of multi-capsule relays.

In accord with these objectives the relay features generally: an integrally molded support means or bobbin 'which has a plurality of hollows or circular apertures extending lengthwise thereof and two slotted end flanges; an energizing coil which is wound on the bobbin; a plurality of switch capsules which are placed in the corresponding hollows of the molded bobbin; a termination plug or header; electrical connectors between the aforementioned plarts and the header; and a can having its open end closed by the header. The switch capsules may be of the type, for example, disclosed in C. E. Pollard, Jr. P-atent 2,406,036, granted August 20, 1946 and assigned to Bell Telephone Laboratories, Incorporated. v

These and additional objects and features should become more apparent from a perusal of the following detailed description taken in connection with the accompanying drawings of which:

FIG. 1 is a plan View of the relay assembly with the enclosure cover partially cut away to show more clearly the construction of the relay.

FIG. 2 is a cross-sectional View of the relay assembly shown in FIG. 1 and taken substantially along the line 2 2 of that figure.

FIG 3 is a second cross-sectional view of the relay assembly shown in FIG. l and taken substantially along the line 3-3 of that figure.

FIG. 4 is a perspective view of a switch capsule of the type, for example, that is used in the relay assembly shown in FIG. l.

FIG. 5 is a perspective view of the bobbin used in the relay assembly.

Referring now to the drawings and in particular to FIGS. 1, 2 and 3 which illustrate a relay assembly in accordance with the preferred embodiment of the invention. Included in the assembly is a termination plug or header 10 which is known and referred to in the art as an octal-type header. The header consists of a number of pins 15 which are adapted for use with a corresponding female receptacle and which extend from a circular plate 16, normally made of a Bakelite material. The header also includes an expansion lip 17 and a spring member 19. Expansion lip 17 in eiect acts as a flange to the circular plate 16 and accordingly expands the diameter of the header to correspond to the open end of a cylindrical can 11. Assembly of the expansion lip 17 to the header 10 is made `by placing the expansion lip adjacent to shoulder 18 of the circular plate 16 and spring loading it thereto by means of the spring 19, Spring 19, -on the other hand, is positioned between a second shoulder 20 and the expansion lip 17. It is emphasized that although this particular header has been disclosed in connection with the preferred embodiment, this was done merely by way of example and that other types of commercially available headers can be used as well with the relay of the invention. In other words the type of plug used in the relay assembly can depend upon the application in which it is used,

The aforementioned cylindrical can 11 is associated with the header 10 insofar `that the header provides a closure to the open end of the can. Accordingly the can besides being cylindrical shaped includes a flared-out base portion 11A which in assembly extends over the outer edge of the aforementioned expansion lip 17. Thusly, the expansion lip 17 butts up against the inner shoulder provided by the base portion 11A and is secured thereto by crimping or turning over the edge of the base portion against the expansion lip. In this manner then the enclosure of the relay is made.

Also included in the relay assembly is a coil assembly which may be considered a sub-assembly of the relay. This particular assembly is concentrically aligned and spaced from header 19 within can 11 and consists of an integrally molded bobbin 21, one to four switch capsules 13 having contact means contained therein and a coil 22. In connection with this assembly it should be noted that its design is simplified insofar that no tape is required to hold the individual capsules separate from each other. Moreover, it should be observed that the space relationship of the switch capsules 13 with respect to each other and with respect to the bobbin 21 according to the invention is such that once the switch capsules are placed within the circular hollows 30 they are inherently separated and free from relative movement; both axial and lateral. This isbecause there is a snug-fit between the capsules and the circular hollows 30. With the snug-lit there is positive assurance that the switch capsules are completely supported and fixed within the bobbin and no reliance on tape, Wax or any other auxiliary means is necessary for this purpose. Furthermore, the snug-lit between the coil assemblys components makes the relay of the invention more shock and Vibration resistant. This is because these forces, that is the shock and vibration sessies dissimulated forces, are absorbed by the entire unit and not by only certain components of the unit causing relative movement therebetween. Also the bobbin itself contains more mass than bobbins of the prior art and thus is a better absorber of shock.

The assembly furthermore includes electrical connectors 14, which terminate in the pins l5. Certain connectors extend along the coil 22 while certain others extend between the header and the coil assembly. More specifically, the connectors are connected to reed members 29, extending from both ends of the switch capsules I3, and to the pins 15. The electrical connectors le thus serve as the media-through which the switch capsules are connected to the header and ultimately to an external circuit not shown.

FIG. shows in detail the configuration of the aforementioned molded bobbin 2l.. The bobbin is made of an insulating material, for instance a plastic material, and includes a spool portion 23, which is basically a solid round rod having four circular hollows 3ft extending lengthwise, therethrough, and two slotted end flanges 24. Each of the circular hollows are adapted to receive a corresponding switch capsule 13, preferably of the type aforementioned. This does not necessarily mean therefore that each hollow requires a switch capsule in order for the relay to operate. It was for this reason that according to the embodiment only two switch capsules are shown. In other words, this was merely illustrative and that from one to four switch capsules could have as well been shown. Therefore, the bobbin used in the relay can be a standard component to four different relay variations: a single capsule type, a two capsule type, a three capsule type and a four capsule type. This standardization of parts in a number of related relays reduces their unit cost of manufacture.

Flanges 24, the other elements of the bobbin, are preferably circular-shaped having a plurality of slots 26 and 27 equally spaced around their peripheries. The slots differ in length in accordance with their purpose. Whereas slots 26 serve to position and embrace the electrical connectors along a neat path over the coil, slots 27 serve primarily to provide the coil leads with a direct inlet and outlet pass to and from the coil area. To illustrate, the coil leads are brought into the bobbin at the base of the spool 23 in a plane parallel to the plane of the spools external surface. Thus, the coil leads or windings do not have to be brought around an edge of a flange and be subjected to possible sheer forces. Moreover, in cases where there is more than one winding in the coil and the coil leads can be brought out or brought in immediately from 4the coil area as the slots Z7 extend over the entire depth of the coil regardless of the number of turns. This arrangement then eliminates the need for insulating the ends of a winding in order to prevent it from shorting out against other turns of the winding.

FIG. 3 illustrates how the coil 22, the electrical connectors 14, and protective cloth 25 are all kept within the area confines of the bobbin. This feature reduces the chance of possible damage to the relay components =during assembly and could for example reduce the unit cost as less production rejects would occur. As to the protective cloth 25, it is wound with one or more turns around the coil assembly after the capsules are connected by means of the connectors 14 in order to provide protection to the windings. The protective cloth 25, for example, may be what is referred to in the art as empire cloth.

FIG. 4 illustrates the configuration of a switch capsule that may be used with the relay assembly. It contains -reed members 29 extending through both ends of a vitreous elongated capsule 2S and contact means (not shown). Although the contact means described in connection with the preferred embodiment are the mercury contact type .other encapsulated types may also be used.

In contrast to prior art relays the particular embodil ment shown does not use a wax or an epoxy material within any portion of the relay enclosure, not even between the coil assembly and the header assembly. However, under extreme conditions or certain environments it may be nonetheless desirable, in an effort to obtain maximum shock resistance to use such material within the relay enclosure. In these situations wax could be used around the coil assembly so as to support it with respect to the header and the enclosure can. Even here, however, there is an advantage to the construction of the particular relay in that less wax is needed to lill the voids in the relay enclosure and consequently the cost `of manufacture is reduced. This is because no wax or an epoxy material can flow around the capsules only between the header and the coil assembly.

One embodiment of the invention has been disclosed and described in detail however it is to be understood that this was done merely by way of example and not as a limitation to the scope yof the invention as hereinafter claimed:

What is claimed is:

3l. An electromagnetic switching device comprising: a switching assembly, a header assembly, a plurality of elec trical connectors extending between said switching assembly and said header assembly, and an enclosure can; said switching assembly comprising a bobbin made of mol-ded insulating material having a cylindrical coil and switch supporting portion and two end flanges formed integrally therewith, said coil and switch supporting portion being solid except for at least two apertures `of substantially constant diameter extending lengthwise through said coil and switch supporting portion and said flanges, an energizing coil wound on said coil and switch supporting portion between said flanges, sealed switches each having a capsule and contact means contained therein operable in response to energizatlon of said coil, each of said switch capsules individually positioned within one of said apertures and each having a diameter substantially equal to the diameter of said aperture to fix said switch capsules in said coil and switch supporting portion; said header assembly disposed concentrically with said coil and switching assembly and in spaced relationship to one of said flanges; first ones of said connectors connecting said switch capsules with said header assembly and extending in a substantially longitudinal direction across said coil an-d second o-nes of said connectors connecting said coil with said header assembly; said enclosure can having an open end which `receives said header assembly to co-mplete the enclosure of said device.

2. An electromagnetic switching device as claimed in claim l wherein said flanges each include a plurality of slots spaced along the periphery and penetrating radially inward to varying depths, the limit of such penetra-tion be'- ing the radius of said coil and switch supporting portion of said bobbin, certain of said slots receiving atleast certain ones of said first connectors and others receiving at least certain ones of said second connectors, eachof said slots supporting one of said connectors within the peripheries of said flanges thereby allowing said coil and said connectors to be covered and protected together.

3. An enclosed electromagnetic switching devi-ce cornprising: a bobbin made of insulating material and including a spool portion and two end flanges having a plurality `of radially extending slots of varying depths spaced along their periphery and formed integrally with said spool portion, said spool portion and said end flanges having four circular apertures of substantially constant diameter extending lengthwise therethrough; an energizing coil wound on said spool portion between said flanges; four encapsulated switch capsules each having contact means contained therein which are actuated in response to the energizing of said coil, said switch capsules positioned within said apertures and of a diameter substantially equal to the diameter of said apertures to fix said switch capsules in said apertures; termination means positioned concentrically with respect to said bob-bin and in a spaced relationship from one of said ilanges; wire means received by said slots and certain ones thereof connected to said switch capsules and others connected to said coil and ex tending through said termination means; and a cylindrical can having a naturally opened end which receives said termination means to complete the enclosure of said device.

References Cited by the Examiner UNITED STATES PATENTS 2,519,463 8/1950 Harrison 200-112 2,889,424 6/ 1959 Glore et al. 20D-87 2,949,591 8/1960 Craige 336-208 X ROBERT K. SCHAEFER, Primary Examiner. H. HO'HAUSER, Assistant Examiner. 

1. AN ELECTROMAGNETIC SWITCHING DEVICE COMPRISING: A SWITCHING ASSEMBLY, A HEADER ASSEMBLY, A PLURALITY OF ELECTRICAL CONNECTORS EXTENDING BETWEEN SAID SWITCHING ASSEMBLY AND SAID HEADER ASSEMBLY, AND AN ENCLOSURE CAN; SAID SWITCHING ASSEMBLY COMPRISING A BOBBIN MADE OF MOLDED INSULATING MATERIAL HAVING A CYLINDRICAL COIL AND SWITCH SUPPORTING PORTION AND TWO END FLANGES FORMED INTEGRALLY THEREWITH, SAID COIL AND SWITCH SUPPORTING PORTION BEING SOLID EXCEPT FOR AT LEAST TWO APERTURES OF SUBSTANTIALLY CONSTANT DIAMETER EXTENDING LENGTHWISE THROUGH SAID COIL AND SWITCH SUPPORTING PORTION AND SAID FLANGES, AN ENERGIZING COIL WOUND ON SAID COIL AND SWITCH SUPPORTING PORTION BETWEEN SAID FLANGES, SEALED SWITCHES EACH HAVING A CAPSULE AND CONTACT MEANS CONTAINED THEREIN OPERABLE IN RESPONSE TO ENERGIZATION OF SAID COIL, EACH OF SAID SWITCH CAPSULES INDIVIDUALLY POSITIONED WITHIN ONE OF SAID APERTURES AND EACH HAVING A DIAMETER SUBSTANTIALLY EQUAL TO THE DIAMETER OF SAID APERTURE TO FIX SAID SWITCH CAPSULES IN SAID COIL AND SWITCH SUPPORTING PORTION; SAID HEADER ASSEMBLY DISPOSED CONCENTRICALLY WITH SAID COIL AND SWITCHING ASSEMBLY AND IN SPACED RELATIONSHIP TO ONE OF SAID FLANGES; FIRST ONES OF SAID CONNECTORS CONNECTING SAID SWITCH CAPSULES WITH SAID HEADER ASSEMBLY AND EXTENDING IN A SUBSTANTIALLY LONGITUDINAL DIRECTION ACROSS SAID COIL AND SECOND ONES OF SAID CONNECTORS CONNECTING SAID COIL WITH SAID HEADER ASSEMBLY; SAID ENCLOSURE CAN HAVING AN OPEN END WHICH RECEIVES SAID HEADER ASSEMBLY TO COMPLETE THE ENCLOSURE OF SAID DEVICE. 